نوآوری‌های صنعتی

نوآوری‌های صنعتی

یکپارچه‌سازی زمان‌بندی تولید، برنامه‌ریزی نگهداری تعمیرات و کنترل کیفیت با زمان‌های آماده‌سازی وابسته به توالی و زمان‌های پردازش قابل کنترل

نوع مقاله : مقاله پژوهشی

نویسندگان
1 گروه مهندسی صنایع، واحد بناب، دانشگاه آزاد اسلامی، بناب، ایران.
2 گروه مهندسی صنایع، واحد علوم و تحقیقات، دانشگاه آزاد اسلامی، تهران، ایران.
3 گروه مهندسی صنایع، واحد قزوین، دانشگاه آزاد اسلامی، قزوین، ایران.
چکیده
ازآنجایی‌که سیستم‌های تولیدی مدام نیاز به جلوگیری کاهش بازدهی دارند، و یکی از مولفه‌های اصلی حفظ راندمان اجرای مناسب سیستم کنترل کیفیت است. لذا در سیستم‌های تولید یکپارچه‌سازی زمان‌بندی تولید، برنامه‌ریزی نگهداری و تعمیرات و کنترل کیفیت ضروری است در این تحقیق سعی شده است با ارائه یک مدل توسعه‌یافته زمان‌بندی تولید تک‌ماشینی با زمان‌های آماده‌سازی وابسته به‌توالی، زمان‌های پردازش در یک سیستم یکپارچه ارائه گردد. این مدل با دو هدف؛ دست‌یابی به تولیدی یکنواخت یا کمینه‌سازی تفاوت میان بیشینه و کمینه تولید محصول خاص در یک دوره تولیدی و کمینه کردن کل هزینه‌های درگیر در فرایند تولید اعم از هزینه راه‌اندازی، تولید محصول، کمبود، موجودی، بازرسی اقلام تولیدی و هزینه‌های نت (شامل نت پیش‌گیرانه و تعمیرات اساسی) مدلسازی شده است. نتایج حاصل از پیاده‌سازی مدل در یک مطالعه موردی نشان داد اولاً رابطه کاملاً مستقیمی بین حجم اقلام تولیدی برای هر محصول در هر دوره با تعداد اقلام نامنطبق هر دوره وجود دارد. ثانیاً برنامه‌ریزی برای نگهداری و تعمیرات پیشگیرانه هزینه کمتری نسبت به تعمیرات اساسی دارد. همچنین تعداد اقلام نامنطبق هر دوره برای هر محصول در دوره‌های مختلف متأثر از زمان‌بندی تولید و نگهداری و تعمیرات محصولات است. به طوری که مدیر تولید باید در برنامه‌ریزی تولید این محصولات با توجه به زمان‌های قابل‌پردازش توجه داشته باشند.
کلیدواژه‌ها

عنوان مقاله English

Integrating Production Scheduling, Maintenance Planning and Quality Control with Sequence-dependent Setup Times, Controllable Processing Times and Outsourcing the Part of Production

نویسندگان English

Mahdi Yousefi Nejad Attari 1
Elham Saghafi 2
Leila Rostamian 3
1 Department of Industrial Engineering, Bon.C., Islamic Azad University, Bonab, Iran.
2 Department of Industrial Engineering, Science and Research Branch, Islamic Azad University, Tehran, Iran.
3 Department of Industrial Engineering, Qaz.C., Islamic Azad University, Qazvin, Iran.
چکیده English

Since production systems constantly need to prevent efficiency decline, and one of the main components of maintaining efficiency is the proper implementation of the quality control system. Therefore, in production systems, it is essential to integrate production scheduling, maintenance and repair planning, and quality control. In this research, an attempt has been made to present processing times in an integrated system by presenting an advanced model of single-machine production scheduling with sequence-dependent setup times. This model has been modeled with two objectives: achieving uniform production or minimizing the difference between the maximum and minimum production of a specific product in a production period, and minimizing the total costs involved in the production process, including setup costs, product production, shortages, inventory, inspection of manufactured items, and maintenance costs (including preventive maintenance and major repairs). The results of implementing the model in a case study showed that, first, there is a completely direct relationship between the volume of manufactured items for each product in each period and the number of non-conforming items in each period. Second, planning for preventive maintenance and repairs is less expensive than major repairs. Also, the number of non-conforming items in each period for each product in different periods is affected by the timing of production and maintenance and repairs of products. So that the production manager should pay attention to the processing times in planning the production of these products.

کلیدواژه‌ها English

Integrated scheduling
Maintenance planning
Quality control
Sequence-dependent setup time
Controllable processing time
multi-objective optimization
[1]    Monma CL, Potts CN. Analysis of heuristics for preemptive parallel machine scheduling with batch setup times. Operations Research. 1993;41(5):981–993.
[2]    Karimi-Nasab M, Modarres M, Seyedhoseini SM. A self-adaptive PSO for joint lot sizing and job shop scheduling with compressible process times. Applied Soft Computing. 2015;27:137–147.
[3]    Wang JB, Xia ZQ. Single machine scheduling problems with controllable processing times and total absolute differences penalties. European Journal of Operational Research. 2007;177(1):638–645.
[4]    Kayvanfar V, Komaki GM, Aalaei A, Zandieh M. Minimizing total tardiness and earliness on unrelated parallel machines with controllable processing times. Computers & Operations Research. 2014;41:31–43.
[5]    Hsieh PH, Yang SJ, Yang DL. Decision support for unrelated parallel machine scheduling with discrete controllable processing times. Applied Soft Computing. 2015;30:475–483.
[6]    Karimi-Nasab M, Aryanezhad MB. A multi-objective production-smoothing model with compressible operating times. Applied Mathematical Modelling. 2011;35(7):3596–3610.
[7]    Karimi-Nasab M, Ghomi SF. Multi-objective production scheduling with controllable processing times and sequence-dependent setups for deteriorating items. International Journal of Production Research. 2012;50(24):7378–7400.
[8]    Yin Y, Wu WH, Cheng TCE, Wu CC. Single-machine scheduling with time-dependent and position-dependent deteriorating jobs. International Journal of Computer Integrated Manufacturing. 2015;28(7):781–790.
[9]    Naderi B, Zandieh M, Fatemi Ghomi SMT. A study on integrating sequence dependent setup time flexible flow lines and preventive maintenance scheduling. Journal of Intelligent Manufacturing. 2009;20(6):683–694.
[10] Sortrakul N, Nachtmann HL, Cassady CR. Genetic algorithms for integrated preventive maintenance planning and production scheduling for a single machine. Computers in Industry. 2005;56:161–168.
[11] Chen JS. Scheduling of nonresumable jobs and flexible maintenance activities on a single machine to minimize makespan. European Journal of Operational Research. 2008;190(1):90–102.
[12] Pan E, Wang G, Xi L, Chen L, Han X. Single-machine group scheduling problem considering learning, forgetting effects and preventive maintenance. International Journal of Production Research. 2014;52:5690–5704.
[13] Mellouli R, Sadfi C, Chu C, Kacem I. Identical parallel machine scheduling under availability constraints to minimize the sum of completion times. European Journal of Operational Research. 2008;197:1150–1165.
[14] Motaghedi-Larijani A, Haddad R, Sabri-Laghaie K. A new single-machine scheduling problem with setup time, job deterioration and maintenance costs. International Journal of Management Science and Engineering Management. 2011;6:284–291.
[15] Wang S. Bi-objective optimization for integrated scheduling of single machine with setup times and preventive maintenance planning. International Journal of Production Research. 2013;51:3719–3733.
[16] Wong CS, Chan FTS, Chung SH. A joint production scheduling approach considering multiple resources and preventive maintenance tasks. International Journal of Production Research. 2013;51:883–896.
[17] Lee WC. A note on single-machine make-span scheduling with deteriorating jobs and scheduled maintenance. Journal of Information and Optimization Sciences. 2007;28:469–477.
[18] Pan E, Liao W, Xi L. Single-machine-based production scheduling model integrated preventive maintenance planning. International Journal of Advanced Manufacturing Technology. 2010;50:365–375.
[19] Rastgar A, Rezaeian J, Fattahi P. Integrated modeling of production planning and maintenance scheduling in hybrid job-shop environment. Pajouhesh-haye Novin dar Tasmim-giri. 1401;2:1–27. [In Persian].
[20] Hosseini M. Integrated modeling and solution of production planning and maintenance scheduling in a bi-objective framework considering customer dissatisfaction. Motaleat Modiriat Sanati. 1399;56:129–169. [In Persian].
[21] Rezaeian J, Razaghi A. Two-stage flow shop assembly line scheduling considering job aging effect, job availability constraints and preventive maintenance. Mohandesi Sanaye. 1397;1:49–60. [In Persian].
[22] Haji-Pour V, Mousavi M. Integrated production and maintenance optimization considering carbon emission. Mohandesi Sanaye va Modiriat Sharif. 1399;2(1):25–36. [In Persian].
[23] Mishra K, Shrivastava A, D. Integration of production scheduling and group maintenance planning in multi-unit system employing TLBO algorithm. Procedia CIRP. 2020;93:949–954.
[24] Yang H, Li W, Wang B. Joint optimization of preventive maintenance and production scheduling for multi-state production systems based on reinforcement learning. Reliability Engineering & System Safety. 2021;214:107713.
[25] Merghem M, Haoues M, Mouss K, Dahane M, Senoussi A. Integrated production and maintenance planning in hybrid manufacturing-remanufacturing system with outsourcing opportunities. Procedia Computer Science. 2023;217:1487–1496.
[26] Chekoubi Z, Ettahiry N, Dellagi S, Trabelsi W, Majdouline I. Integrated production and maintenance scheduling with environmental and operational considerations. IFAC-PapersOnLine. 2022;55:1369–1374.
[27] Sinisterra WQ, Cavalcante CAV. An integrated model of production scheduling and inspection planning for resumable jobs. International Journal of Production Economics. 2020;227:31–37.
[28] Salahi F, Daneshvar A, Homayounfar M, Pourghader-Chobar A. Presenting an integrated model for production planning and preventive maintenance scheduling considering uncertainty of parameters and disruption of facilities. Industrial Management Perspective. 2023;13(1):105–140.
[29] Lv X, Shi L, He Y, He Z. Joint optimization of production, inspection, and maintenance under finite time for smart manufacturing systems. Reliability Engineering & System Safety. 2025;253:110490.
[30] Wang Y, Xia T, Xu Y, Si G, Wang D, Pan E, Xi L. Quality-centered production and maintenance optimization for advanced manufacturing systems under uncertainty. Reliability Engineering & System Safety. 2024;245:110025.
[31] Lv X, Shi L, He Y, He Z. Joint optimization of production, inspection, and maintenance under finite time for smart manufacturing systems. Reliability Engineering & System Safety. 2025;253:110490.
[32] Joyaardakani H, Khakzar-Bafrouyi M. Economic design of integrated maintenance control and management chart in Kish Wood Industries. Pajouhesh-haye Novin dar Tasmim-giri. 1401;1:116–132. [In Persian].
[33] Rasaei H, Fallah-Nejad MS, Zare-Mehrjardi Y. Integration of maintenance decisions and process control in a serial production system. Majale-ye Irani Motaleat Modiriat. 1395;2:379–405. [In Persian].
[34] Tambe P, Kulkarni M. A reliability based integrated model of maintenance planning with quality control and production decision for improving operational performance. Reliability Engineering & System Safety. 2022;226:108681.
[35] Wan Q, Chen L, Zhu M. A reliability-oriented integration model of production control, adaptive quality control policy and maintenance planning for continuous flow processes. Computers & Industrial Engineering. 2022;176:108985.
[36] Duffuaa S, Kolus A, Al-Turki U, El-Khalifa A. An integrated model of production scheduling, maintenance and quality for a single machine. Computers & Industrial Engineering. 2020;142:106239.
[37] Pandey D, Kulkarni M, Vrat P. A methodology for joint optimization for maintenance planning, process quality and production scheduling. Computers & Industrial Engineering. 2011;61:1098–1106.
[38] Hadian SM, Farughi H, Rasay H. Joint planning of maintenance, buffer stock and quality control for unreliable, imperfect manufacturing systems. Computers & Industrial Engineering. 2021;157:107304.
[39] Rivera-Gómez H, Gharbi A, Kenné JP, Ortiz-Zarco R, Corona-Armenta JR. Joint production, inspection and maintenance control policies for deteriorating system under quality constraint. Journal of Manufacturing Systems. 2021;60:585–607.
[40] Lopes R. Integrated model of quality inspection, preventive maintenance and buffer stock in an imperfect production system. Computers & Industrial Engineering. 2018;126:650–656.
[41] Cheng G, Li L. Joint optimization of production, quality control and maintenance  for serial-parallel multistage production systems. Reliability Engineering & System Safety. 2020;204:107146.
[42] Ait-El-Cadi A, Gharbi A, Dhouib K, Artiba A. Integrated production, maintenance and quality control policy for unreliable manufacturing systems under dynamic inspection. International Journal of Production Economics. 2021;236:108140.
[43] Tasias AK. Integrated quality, maintenance and production model for multivariate processes: a Bayesian approach. Journal of Manufacturing Systems. 2022;63:35–51.
[44] Beheshti-Fakher H, Nourelfath M, Gendreau M. Integrating production, maintenance and quality: A multi-period multi-product profit-maximization model. Reliability Engineering & System Safety. 2018;170:236–248.
[45] Bouslah B, Gharbi A, Pellerin R. Integrated production, sampling quality control and maintenance of deteriorating production systems with AOQL constraint. Omega. 2016;61:110–126.
[46] Salmasnia A, Hafeziyan R. Integrated optimization model of production planning, quality control and maintenance for multi-product systems. In: 2nd International Conference on Modern Developments in Management, Economics and Accounting. 1397. [In Persian].
[47] Ma’navi-Zadeh N, Azizi-Javan A. A new approach in joint optimization of maintenance, process quality and production planning. In: 10th International Conference on Industrial Engineering. 1392. [In Persian].
[48] Jafarzanjani H, Zandieh M, Khalilzadeh M. Stochastic programming model and Benders decomposition approach for integrated production and maintenance planning in multi-factory production systems. Journal of Industrial Engineering Research in Production Systems. 1399; 16:77–93. [In Persian].

  • تاریخ دریافت 15 آبان 1404
  • تاریخ بازنگری 16 دی 1404
  • تاریخ پذیرش 27 بهمن 1404